Kohler Co.'s tours offer close look at this state fixture

By Mary Bergin

When I met Lowell Kappers in 2005, he was 69, had worked at the Kohler Co. for 44 years and had yet to truly retire. That was by choice, and not much has changed.

The Oostburg man used to wear an air-fed helmet to protect his breathing and plug his ears with cotton to dull the near-constant noise. He worked as a cast iron grinder until 1999. Now he occasionally leads visitors on tours of the factory.

These free tours are not quick glimpses of people at work from behind an observation glass. The Kohler tour is unusual because it lasts 3.5 hours and gets relatively close to the steam, dust and red-hot materials that are a part of the daily production of plumbing fixtures and bathroom furnishings.

This introduction takes visitors through the factory's pottery, brass and cast iron divisions. The sightseeing is scheduled during mornings, which is especially necessary in summer when the factory can get hot.

The pottery kilns, for example, average 2,450 degrees.

"Castings are a creamy white when they go into a kiln," Kappers says. "If color is embedded in them, it will show up at the end of the process."

The addition of decorative elements can be a delicate, painstakingly intricate procedure.

Although products from sinks to toilets are available in dozens of colors, Kappers says the majority of sales are for white, almond or biscuit tones.

We later watch "Herman," the monstrous robotic equipment that manufactures and moves one bathtub mold per minute, under the guidance and monitoring of humans.

"The molds come together like a ham sandwich," Kappers says, "filled with molten iron from beginning to end."

We stand near glowing-red tubs and watch enamel coating sprayed by hand.

"I call that a hot tub," Lowell deadpans.

Up to four artists at a time are at work in the factory. They use industrial materials and equipment to create unusual murals and sculptures through an Arts in Industry program.

As the artists and employees interact, they tend to gain insight and respect for each other's work.

The company has offered factory tours since the 1920s, says Cindy Howley, Kohler Design Center manager.

In 2008, 9,000 people took the tour.

Retired employees lead the tours. These individuals share knowledge from their average 40 years at the Kohler Co.

"We feel that if people see what goes into the making of our products, they'll be totally sold on the fine craftsmanship," says Howley, who coordinates the tours.

No more than eight people can take a tour to ensure safety. Participants must be at least 14 years old and wear close-toed shoes.